1991 MITSUBISHI 3000GT service

CLUTCH - Clutch Cover and Disc
6CLOl f
Lubricant: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
7CLOOO8
Lubricant: MITSUBISHI genuine grease
Part No. 0101011 or eauivalent
6CL03:
Lubricant: MITSUBISHI genuine greasePart No. 0101011 or equivalent
SERVICE POINTS OF REMOVALMZlGBAK
1.REMOVAL OF CLUTCH COVER ASSEMBLY / 2. CLUTCH
DISCDiagonally loosen bolts which attach clutch cover to
flywheel. Back off bolts in succession, one or two turns at a
time, to avoid bending cover flange.
CautionDO NOT clean clutch disc or release bearing with
d
cleaning solvent.TSB Revision
1

21-22CLUTCH - Clutch Cover and Disc
APPLYgrease
6CLOlE
lir#LClutch disc
Clutch cover
assembly
v-l6CL02EITSB Revision
SERVICE POINTS OF INSTALLATIONMZIGDAU5. APPLICATION OF GREASE TO RELEASE FORK
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact
withthe release bearing.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
CautionWhen installing the clutch, apply grease to each
part, but be careful not to apply excessive grease;excessive grease will cause clutch slippage and
shudder.(2) Apply a coating of the specified grease to the end of the
release cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
4.APPLICATION OF GREASE TO CLUTCH RELEASE BEAR-ING (FWD)
Pack the inner surface of the clutch release bearing and the
groove with the specified grease.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
2. APPLICATION OF GREASE TO CLUTCH DISC
/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
(2) Using the universal clutch disc aligner, position the
clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.I

22-1
iv,MANUAL ~
TRANSAXLE
~
I
CONTENTSM22AA. -
MANUAL TRANSAXLE . . . . . . . . . . . .._...48INPUT SHAFT ASSEMBLY_..________.............: . . . . . . . . . . . . . . . . . . . . . . . . . .30
GENERAL INFORMATION....................................................48
SERVICE ADJUSTMENT PROCEDURES
............................51
Drive Shaft OilSealsReplacement....................................
52Speedometer Cable Replacement....................................
53Transfer Oil Seal Replacement............................................53Transmission Oil Level Inspection....................................51Transmission Oil Replacement............................................51
SHIFT LEVER ASSEMBLY....................................................
53
SPECIAL TOOLS........................................................................50
SPECIFICATIONS
....................................................................49
General Specifications........................................................49Lubricants............................................................................49
TRANSAXLE ASSEMBLY....................................................56,60
TRANSAXLE CONTROL*........................................................54
TRANSFER ASSEMBLY
........................................................59
MANUAL TRANSAXLE ....................2
CLUTCH HOUSING ASSEMBLY............................................46
DIFFERENTIAL ASSEMBLY
....................................................43
5TH SPEED SYNCHRONIZER ASSEMBLY
........................28
GENERAL INFORMATION
....................................................2INTERMEDIATE GEAR ASSEMBLY
....................................
OUTPUT SHAFT ASSEMBLY................................................
SERVICE ADJUSTMENT PROCEDURES............................
Drive Shaft Oil Seals Replacement....................................Speedometer CableReplacement....................................Transmission Oil Level Inspection....................................Transmisston Oil Replacement............................................
SHIFT LEVER ASSEMBLY....................................................
SHIFT RAILS AND FORKS....................................................
SPECIAL TOOLS........................................................................
SPECIFICATIONS....................................................................
General Specifications........................................................
Lubricants............................................................................
Sealants and Adhesives........................................................Service Specifications........................................................
Snap Ring (for Adjustment) and Spacer............................
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................
TRANSAXLE ASSEMBLY _____...._........__....................................
TRANSAXLE CONTROL*. . ..________.___.._ ..__._.__.__...............
36
41
9
10
9
9
9
13
42
6
3z
63
3
45
14
11TROUBLESHOOTING
___.._______._____.......,..................................8
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3000GT.(2)The SRS includes the following components: impact sensors, SRS diagnosis unit: SRS warning light, air bagmodule, clock spring, interconnecting wiring. Other SRS-related components (that may have to be
removed/installed in connection with SRS service or maintenance) are indicated in the table of contents byan asterisk (*).
WARNING!(1)Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (fromrendering the
SRS inoperative).(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B
-Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of theSRS or any SRS-related component.

MANUAL TRANSAXLE - Specifications22-3
SPECIFICATIONS
L
GENERAL SPECIFICATIONSM22CA.A
items
Model
Applicable engine
Type
Gear ratio
1 st
2nd
3rd
4th
5th
Reverse
Final reduction ratio
Speedometer gear ratio (driven/drive)
Oil quantityliters (qts.)
Specifications
F5M33-2-SNZR
6G72-DOHC MPI
5-speed transaxle floor shift
3.090
1.833
1.217
0.888
0.741
3.166
4.153
28136
2.3 (2.4)
SERVICE SPECIFICATIONSM22CB-A
mm (in.)
L.J
Items
Standard value
Transaxle
Input shaft end play
Input shaft rear bearing end play
Intermediate gear bearing end play
Intermediate gear preload
Output shaft preload
Differential
Differential case preload
Differential pinion backlash
Limit
Specifications
0 - 0.05 (0 - ,002)
0.01 - 0.09 i.0004 - ,004)0.01 -0.14 (.0004-
,006)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - .004)
0.025 - 0.150 (.OOl - ,006)
Synchronizer ring and clutch gear clearance0.5 (.02)
SNAP RING (FOR ADJUSTMENT) AND SPACERM22CF.A
Part name
Spacer
(For adjustment of input shaft end play)Thickness mm (in.)
0.80
i.0315)
0.83 (.0327)
0.86(.0338)
0.89t.0350)
0.92
(.0362)
Identificationsymbol
80
83
86
89
92
Part No.
MD727661
MD720937
M D720938
MD720939
MD720940TSB Revision

MANUAL TRANSAXLE - Service Adiustment Procedures22-9
110*u011009FO12
SERVICE ADJUSTMENT PROCEDURES
MZZFBAEl
TRANSMISSION OIL LEVEL INSPECTIONRefer to GROUP 00
- Maintenance Service.
TRANSMISSION OIL REPLACEMENTM22FCAI(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transmission oil
to drain.
(3) Refill the transaxle to the proper level with specified
transmission oil. The oil level should be the bottom of the oil
filler hole.
Transmission oil: Hypoid gear oil, SAE 75W-85W con-
forming to API classification GL-4 or
higherC2.3 liters (2.4 pts.)]
SPEEDOMETER CABLE REPLACEMENTMUFEALl
1.Correctly insert the adapter into the instrument panel, and
fasten the new speedometer cable.
2.Install the grommet so that, as shown in the illustration, the
cable attachment part and the projecting part are horizontal.
CautionThe cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
3.At the transaxle end of the speedometer cable, the key joint
should be inserted into the transaxle, and the nut should be
securely tightened.
Caution
If the cable is not correctly and securely connected, it
may cause incorrect indication. by the speedometer, orabnormal noise. Be sure to connect it correctly.
DSB RevisionI

22-10 MANUAL TRANSAXLE - Service Adjustment ProceduresI
I09K5671160024
Oil seallip
* Transaxleside2200037
DRIVE SHAFT OIL SEALS REPLACEMENTM2ZFDAI
(I) Disconnect the drive shaft from the transaxle.
(Refer to GROUP 26
- Drive Shaft.)’ )
(2) Using a flat-tip (-) screwdriver, remove the oil seal.d,(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
The drive shaft oil seal must be installed in the direction
shown.
(4) Apply a coating of the transmission oil to the lip of the oil
seal.
Transmission oil: Hypoid gear oil, SAE 75W-90 or
75W-85W conforming to API classi-
fication GL-4 or higher
‘d
TSB Revision

MANUAL TRANSAXLE - Transaxle Assembly22-15
idPost-installation Operationl Installation of Front Under Cover(Referto GROUP 51 -Front Bumper.)l Supplying of Transmission Oil (Refer to P.22-9.)l Filling of Engine Coolant (Refer to GROUP 14-
Service Adjustment Procedures.)70 Nm
l Checking Operation of Shift Lever at Each Positionl Checking the Operation of the Meters and Gauges26
ft.lbs.09FOO84
4*9. Connection for transaxle mount16. Starter10. Transaxle mount bracket4*17. Drive shaft (Left side),
l * 11. Mounting stopperinner shaft assembly12. Transaxle assembly upper part+* ** 18. Drive shaft (Right side)
coupling bolt19. Transaxle stay (Front bank side)4*13. Connection for tie rod end20. Transaxle stay (Rear bank side)4*14. Connection for lower arm4*21. Transaxle assembly lower part
ball jointcoupling bolt15. Right member4*22. Transaxle assembly
SERVICE POINTS OF REMOVALMZZMBBA6. DISCONNECTION OF THE CLUTCH TUBE BRACKET
AND CLUTCH DAMPER ASSEMBLY
Remove the clutch release cylinder and clutch oil line
bracket installation bolt, and then secure at the body side
without disconnecting the oil line coupling.
1 TSB Revision

MANUAL TRANSAXLE - Transaxle Assemblv22-17
Transaxmount
bracket
OlFOO4518. REMOVAL OF DRIVE SHAFT (RIGHT SIDE)
(1) To remove drive shaft (right side) from transaxle
assembly, apply pry bar to the protrusion.
NOTERemove drive shaft (right side) as an
assemb’ly together
with hub, knuckle, and other parts.
(2) Suspend the removed drive shaft (right side) with wire
or something similar to prevent it from sharply bending
or turning at each joint.
21. REMOVAL OF TRANSAXLE ASSEMBLY LOWER PARTCOUPLING BOLT
/ 22. TRANSAXLE ASSEMBLY
Support transaxle assembly with a transaxle jack and
remove transaxle assembly lower part coupling bolt; then,
lower transaxle assembly.
SERVICE POINTS OF INSTALLATIONM2ZMDAT
18. INSTALLATION OF DRIVE SHAFT (RIGHT SIDE)
ProvisionaHy install the drive shaft (right side) so that the
inboard joint part of the drive shaft (right side) is straight,
and not bent relative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip part of
the transaxle is not damaged by the serrated part of thedrive shaft (right side).
11. INSTALLATION OF MOUNTING STOPPERInstall mounting stopper in the direction shown.
TSB Revision